DCS Foot-Powered Vibrating Table

The DCS Foot-Powered Vibrating Table is a one-person operation
screeding table, manufactured in Nepal since 1987. The vibrating surface and
drive mechanism are mounted on an angle iron frame. Connected to this is a seat,
which is adjustable to suit the tile maker's stature, so that he can sit
comfortably at the table while making the tile. Herocks the two foot pedals back
and forth at an easy speed driving a bicycle wheel, which in turn drives an
eccentric weight assembly beneath the aluminium vibrating surface at a speed of
2500 to 3000 rpm.Careful fitting of all nine sealed bearings ensures easy
operation and long life for the machine. The screeding table has a one year
guarantee.

The screeding frames for tiles (6 and 8 mm thick) are shaped to
provide an "interlock" at the mitre - the diagonal mitre has been replaced by a
dog-legged mitre. The frames also provide nib construction boxes for a wind
proof fixing of all tiles. Experience shows that wind forces are sufficient to
lift tiles, so all tiles are made with a lower fixing nib. A second nib may be
made at the top for special conditions (top line of monoslope roofs, edges with
long overhangs). When they are not needed, these nib boxes can be swung out of
the screeding area (to leave it unobstructed for quick working) and positioned
when needed.

The moulds are 535 mm long concrete elements fixed into
galvanized sheet stacking frames, which also serve to protect the fresh tile
from drying out during setting. DCS sells fitted moulds and frames with the
screeding tables. This ensures that the moulds used are accurate and of good
quality and allows the entrepreneur to start tile production immediately, so
that he soon can produce a demonstration roof to show interested customers and
begin to earn money without delay. He can however, also buy a fibreglass mother
mould, with which he can make his own moulds later (when he has sufficient
experience), in order to replace broken moulds or increase his production
capacity.

In addition to the sereeding table and tile moulds, the
following accessories are supplied:· a set of batching boxes for fast
measurement of cement and sand to correct proportions and workable batch
size;· a set of tile maker's scoops to enable correct batching of the
wet mortar as tiles are made;· a tile thickness gauge for checking
finished tiles according to the standard;· a batten gauge to aid quick
and accurate roof building.Entrepreneurs may purchase extra tools for
quality checking:· standard vessel to measure water for
mixing;· prism mould, loading jig and thickness gauge for checking
mortar strength.DCS also supplies sieves for screening sand and fine
aggregate, shovels, trowels, pliers, tile stack covers, interface plastics etc.

Maintenance

The screeding table is maintenance free for up to 5 years, if
cleaned regularly during tile making. The tile frame and screeding surface must
be cleaned after each tile is screeded, in order to avoid distorting them.
Bearings are protected by seals and cover plates. The bushes for the frame
clamping arms and for the vibrating drive should be lubricated before the
machine is stored for a period of no production, to avoid seizure from rust. The
screeding surface mounting rubbers need replacing every year, as they
absorb/damp vibration when they are perished. Replacement rubbers can be hand
made from a scrap truck type, footwear repairers always have this type of rubber
available.

Moulds need regular cleaning to avoid build-up of spilt mortar.
Daily cleaning with a cloth or handful of fibre is quick and easy. Mortar left
longer can be scraped off without fear of damage to the mould, as it has a hard
surface,

Training

DCS selects prospective entrepreneurs from applicants for an
11-day training course in FCR/MCR. The training is held in Butwal and includes
theory and practical sessions covering· production (including raw
material selection, quality checks),· tile use (roof types,
construction, tile fitting),· entrepreneur motivation,·
marketing skills,· ease reports and a tour to an established tile
producer,· book-keeping,· obtaining finance.

Operating the DCS Vibrating Table

Before production, the tile maker must adjust the seat to enable
him to sit comfortably while working. Also the screeding surface must be
levelled before beginning. A small backrest is provided to give the light
support needed while operating the foot pedals and screeding the mortar.
Pedalling is not heavy work for the operator's legs.

When the mortar has been batched and mixed, the operator sits at
the table, places a plastic interface sheet on the screeding table, then clamps
down the appropriate tile frame. Using the corresponding scoop, a measured lump
of mixed mortar is placed on the screeding table, and then this is trowelled out
to an even thickness within the tile frame, while generating the vibration by
rocking the foot pedals back and forth. When the screed surface is smooth and
level with the screeding frame, the nib on the lower tile end is made by
swinging the nib construction box into place, filling it with mortar under
vibration, and inserting a wire loop for fixing on the supporting roof batten.
Depending on the roof design, some of the tiles will need a second nib on the
upper end, for which another nib box is provided.

After the nibs are made, the plastic sheet with the screeded
mortar is lifted onto the next empty mould. This mould is then moved to the
stack of newly moulded tiles and the position of the screed on the mould is
checked. It is covered with the next mould and screed, or a mould cover if it is
at the top of the stack, to prevent the mortar from drying.

The tiles are removed from the moulds after about 24 hours and
subsequently cured for 2 weeks in water tanks or vapour curing beds.